Pile connection with open collar section

ABSTRACT

Disclosed is a pile connection with an open collar section. The pile connection includes a collar configured to attach to an elongated beam extending along a beam axis, the collar comprising a primary collar section defining a gap, the primary collar section configured to partially surround the elongated beam. The pile connection further includes a first pile sleeve comprising a first inlet, a first outlet, and a first outer surface extending therebetween, at least a portion of the first outer surface attached to the primary collar section, the first pile sleeve configured to receive a first pile.

PRIORITY APPLICATIONS

The present application claims priority to U.S. Provisional Patent Application Ser. No. 63/255,617 entitled “PILE CONNECTION WITH OPEN COLLAR SECTION,” filed on Oct. 14, 2021, which is incorporated hereby by reference in its entirety.

The present application claims priority to U.S. Provisional Patent Application Ser. No. 63/239,472 entitled “MICROPILE CONNECTION WITH OPEN COLLAR SECTION,” filed on Sep. 1, 2021, which is incorporated hereby by reference in its entirety.

FIELD OF THE DISCLOSURE

The disclosure relates to a pile connection and, more particularly, to a pile connection for supporting a vertical pile for a support system (e.g., for solar panels).

BACKGROUND

Installations may require a support structure, whether new or repaired. Such installations may require vertically driven piles, which must be driven into the ground to a required depth to provide sufficient support. Often, a pile is partially driven to a required depth but then hits an obstruction, resulting in a refusal. Other times, a preexisting pile may need further structural support, such as due to environmental changes. Processes for handling such issues are typically slow, intensive, and expensive.

No admission is made that any reference cited herein constitutes prior art. Applicant expressly reserves the right to challenge the accuracy and pertinency of any cited documents.

SUMMARY

Disclosed is a pile connection with an open collar section. The pile connection includes a collar configured to attach to an elongated beam extending along a beam axis, the at least one collar comprising a primary collar section defining a gap, and the primary collar section is configured to partially surround the elongated beam. The pile connection further includes a first pile sleeve comprising a first inlet, a first outlet, and a first outer surface extending therebetween, at least a portion of the first outer surface attached to the primary collar section, and the first pile sleeve is configured to receive a first pile.

One embodiment is directed to a pile connection. The pile connection includes a collar configured to attach to an elongated beam extending along a beam axis, the at least one collar comprising a primary collar section defining a gap. The primary collar section is configured to partially surround the elongated beam. The pile connection further includes a first pile sleeve comprising a first inlet, a first outlet, and a first outer surface extending therebetween. At least a portion of the first outer surface attached to the primary collar section. The first pile sleeve is configured to receive a first pile.

Another embodiment is directed to a support system. The support system includes at least one elongated beam extending along a beam axis and having a first side, a second side, a top, and a bottom surrounding the beam axis. The support system further includes at least one pile connection attached to the at least one elongated beam. The at least one pile connection includes a collar configured to attach to an elongated beam extending along a beam axis. The at least one collar comprises a primary collar section defining a gap. The primary collar section is configured to partially surround the elongated beam. The at least one pile connection further includes a first pile sleeve comprising a first inlet, a first outlet, and a first outer surface extending therebetween, at least a portion of the first outer surface attached to the primary collar section. The first pile sleeve is configured to receive a first pile. The support system further includes a first pile positioned within the first pile sleeve.

Another embodiment is directed to a method for forming a support system. The method includes positioning an elongated beam relative to a ground, the elongated beam extending along a beam axis and having a first side, a second side, a top, and a bottom surrounding the beam axis. The method further includes attaching a pile connection to the elongated beam by inserting the elongated beam through a gap defined by a primary collar section of a collar. The primary collar section is configured to partially surround the elongated beam. The method further includes inserting a first pile into a first pile sleeve of the pile connection and driving the first pile into the ground to fix the elongated beam to the ground. The first pile sleeve is attached to the primary collar section.

Additional features and advantages will be set forth in the detailed description which follows and, in part, will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description and the following detailed description are merely exemplary and are intended to provide an overview or framework for understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s) and, together with the description, serve to explain principles and operation of the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a support system, including a pile connection for vertically fixing an elongated beam.

FIG. 1B is a perspective view of a pile connection to attach to the elongated beam of FIG. 1A.

FIG. 1C is a front top view of the pile connection of FIG. 1B.

FIG. 1D is a rear top view of the pile connection of FIG. 1B.

FIG. 2 is a perspective view of a support system, including the pile connection of FIGS. 1A-1D.

FIG. 3A is a perspective view of a support system, including a pile connection for horizontally fixing an elongated beam.

FIG. 3B is a top view of a pile connection to attach to the elongated beam of FIG. 3A.

FIG. 3C is a front view of the pile connection of FIG. 3B.

FIG. 3D is a side view of the pile connection of FIG. 3B.

FIG. 4 is a view of another embodiment of the pile connection of FIGS. 1A-1D and 3A-3D.

FIG. 5 is a flowchart illustrating an assembly of a support system, including the pile connection of FIGS. 1A-1D and 3A-3D.

DETAILED DESCRIPTION

Reference will now be made in detail to the presently preferred embodiments, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

Terms such as “left,” “right,” “top,” “bottom,” “front,” “back,” “horizontal,” “parallel,” “perpendicular,” “vertical,” “lateral,” “coplanar,” and similar terms are used for convenience of describing the attached figures and are not intended to limit this description. For example, terms such as “left side” and “right side” are used with specific reference to the drawings as illustrated, and the embodiments may be in other orientations in use. Further, as used herein, terms such as “horizontal,” “parallel,” “perpendicular,” “vertical,” “lateral,” etc., include slight variations that may be present in working examples.

It will be understood that, although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element without departing from the scope of the present disclosure. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including” when used herein specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Disclosed is a pile connection with an open collar section. The pile connection includes a collar configured to attach to an elongated beam extending along a beam axis, the at least one collar comprising a primary collar section defining a gap, and the primary collar section is configured to partially surround the elongated beam. The pile connection further includes a first pile sleeve comprising a first inlet, a first outlet, and a first outer surface extending therebetween, at least a portion of the first outer surface attached to the primary collar section, and the first pile sleeve is configured to receive a first pile.

FIGS. 1A-1D are views of a support system 100, including a pile connection. The support system 100 includes a pile connection 102 fixing an elongated beam 104 to the ground 106. The elongated beam 104 may include a first end 107A and a second end 107B opposite the first end 107A with a cross-section extending between the first end 107A and the second end 107B along axis Z. In certain embodiments, the elongated beam 104 is positioned on the ground 106, so that axis Z is generally perpendicular to the ground 106. In certain embodiments, the elongated beam 104 is positioned on the ground 106 so that axis Z is generally parallel to the ground 106.

The support system 100 includes at least one elongated beam 104, at least one pile connection 102, and at least one pile 108A, 108B. It is noted that any reference to “pile” is inclusive of “micropiles” (may also be referred to as mini piles, pin piles, need piles, root piles, etc.), which are deep foundation elements, typically with a diameter between 3-10 inches. Further, any reference to “pile” may instead be specific to “micropiles” instead.

The at least one pile connection 102 is attached to the elongated beam 104. The pile connection 102 includes a first pile sleeve 110A, a second pile sleeve 110B, and a collar 112 configured to attach the first pile sleeve 110A and the second pile sleeve 110B to the elongated beam 104. The collar 112, first pile sleeve 110A, and/or second pile sleeve 110B includes at least one of a circular cross-section, a rectangular cross-section, or a square cross-section.

The first pile sleeve 110A defines a first axis A1 and the second pile sleeve 110B defines a second axis A2. The first pile sleeve 110A is configured to receive a first pile 108A (along the first axis A1), and the second pile sleeve 110B is configured to receive a second pile 108B (along the second axis A2). The first pile 108A is positioned within the first pile sleeve 110A, and the second pile 108B is positioned within the second sleeve 110B. In certain embodiments, the pile connection 102 only includes one pile sleeve 110A, 110B. In certain embodiments, the pile connection 102 only includes two pile sleeves 110A, 110B. In certain embodiments, the first pile sleeve 110A and the second pile sleeve 110B are non-parallel to each other.

In certain embodiments, the at least one elongated beam 104 extends along a beam axis Z and has a plurality of sides 114 surrounding the beam axis Z and defining a channel 120. In certain embodiments, the elongated beam 104 includes structural steel, such as circular tubing, rectangular tubing, square tubing, I-Beam, or W-Beam. In such a configuration, the elongated beam 104 defines a central channel 120. In certain embodiments, the elongated beam 104 includes timber (e.g., rectangular cross-section, square cross-section, etc.).

The pile connection includes a collar 112 and two pile sleeves 110A, 110B. The collar 112 is configured to attach to the elongated beam 104 extending along a beam axis Z. The collar 112 has at least one of a circular cross-section, a rectangular cross-section, or a square cross-section.

The collar 112 includes a primary collar section 130 defining a gap 132. The primary collar section 130 is configured to partially surround the elongated beam 104.

The primary collar section 130 includes a base wall 134, a first sidewall 136A extending from the base wall 134, a second sidewall 136B extending from the base wall 134. The gap 132 is defined between a first front edge 138A of the first sidewall 136A and a second front edge 138B of the second sidewall 136B. The gap 132 is larger than the elongated beam 104 such that primary collar section 130 is configured to receive the elongated beam 104 through the gap 132. The first sidewall 136A includes at least one first mounting hole 140A proximate the first front edge 138A, and the second sidewall 136B includes at least one second mounting hole 140B proximate the second front edge 138B.

The first pile sleeve 110A includes a first inlet 150A, a first outlet 152A, and a first outer surface 154A extending therebetween. At least a portion of the first outer surface 154A is attached to the primary collar section 130. The first pile sleeve 110A is configured to receive a first pile 108A. The second pile sleeve 110B includes a second inlet 150B, a second outlet 152B, and a second outer surface 154B extending therebetween. At least a portion of the second outer surface 154B is attached to the primary collar section 130. The second pile sleeve 110B is configured to receive a second pile 108B.

In certain embodiments, the pile connection 102 includes two pile sleeves 110A, 110B. Each of the first and second pile sleeves 110A, 110B may have a rectangular cross-section. In certain embodiments, the first and second pile sleeves 110A, 110B are non-parallel to each other. In certain embodiments, the first and second pile sleeves 110A, 110B are aligned in a common plane. The first and second pile sleeves 110A, 110B extend from a top edge of the collar 112 to a bottom edge of the collar 112. The first and second pile sleeves 110A, 110B are both angled to extend from the base wall 134 to the first and second front edges 138A, 138B. In other words, the first and second pile sleeves 110A, 110B are angled in the same direction.

In certain embodiments, the first pile sleeve 110A relative to the first sidewall 136A is at a same angle as the second pile sleeve 110B relative to the second sidewall 136B. Further, the first pile sleeve 110A relative to the base wall 134 is at a same angle as the second pile sleeve 110B relative to the base wall 134.

FIG. 2 is a view of a support system 100 including the pile connection 102 of FIGS. 1A-1D. The elongated beam 104 extends along a beam axis Z. The at least one pile connection 102 is attached to the at least one elongated beam 104. The pile connection 102 includes a collar 112 configured to attach to the elongated beam 104. The collar 112 includes a primary collar section 130 defining a gap 132. The primary collar section 130 partially surrounds the elongated beam 104. The pile connection 102 includes a first pile sleeve 110A having a first inlet 150A, a first outlet 152A, and a first outer surface 154A extending therebetween. At least a portion of the first outer surface 154A is attached to the primary collar section 130. The pile connection 102 includes a second pile sleeve 110B having a second inlet 150B, a second outlet 152B, and a second outer surface 154B extending therebetween. At least a portion of the second outer surface 154B is attached to the primary collar section 130. A first pile 108A is positioned within the first pile sleeve 110A, and a second pile 108B is positioned within the second pile sleeve 110B.

It is noted that the elongated beam may be hollow and include mounting holes to receive fasteners. In particular, a fastener may be inserted through the mounting holes 140A, 140B of the pile connection 102 and the elongated beam 104 to attach the pile connection 102 to the elongated beam 104.

FIGS. 3A-3D are views of another embodiment of a pile connection 102′ of FIGS. 1A-1D for attachment to an elongated beam 104′. In this configuration, the elongated beam 104′ is configured to be mounted horizontally relative to the ground 106.

In this embodiment, first and second pile sleeves 110A′, 110B′ extend from a base wall 134 to top edge of the collar 112. The first and second pile sleeves 110A′, 110B′ extend in opposite directions from one another (i.e., front to back). A first axis of the first pile sleeve 110A′ is non-parallel to a first plane defined by the first sidewall 136A. A second axis of the second pile sleeve 110B′ is non-parallel to a second plane defined by the second sidewall 136B. Further, in this embodiment, the inlets 150A, 150B of the first and second pile sleeves 100A′, 110B′ are closer to the first and second sidewalls 136A, 136B, respectively, than the outlets 152A, 152B of the first and second pile sleeves 110A′, 110B′.

FIG. 4 is a view of another embodiment of the pile connection 102 of FIGS. 1A-1D and 3A-3D. The pile connection 102 includes a collar 112 having a primary collar section 130 and a secondary collar section 300. Fasteners 302 are used to connect the primary collar section 130 and the secondary collar section 300. In this way, the primary collar section 130 and the secondary collar section 300 fully surround the elongated beam 104. Such a configuration may be used to attach the pile connection 102 to the elongated beam 104 when a fastener 302 cannot be attached directly to the elongated beam 104, such as when using a solid (non-hollow) elongated beam 104.

FIG. 5 is a flowchart illustrating an assembly of a support system including the pile connection of FIGS. 1A-1D and 3A-3D. The method includes positioning an elongated beam 104 relative to a ground (500). The elongated beam 104 extends along a beam axis Z. The method further includes attaching a pile connection 102 to the elongated beam 104 by inserting the elongated beam 104 through a gap 132 defined by a primary collar section 130 of a collar 112 (502). The primary collar section 130 is configured to partially surround the elongated beam 104. The method further includes inserting a first pile 108A into a first pile sleeve 110A of the pile connection 102 and driving the first pile 108A into the ground 106 to fix the elongated beam 104 to the ground 106 (504). The first pile sleeve 110A is attached to the primary collar section 130.

In certain embodiments, attaching a pile connection 102 to the elongated beam 104 further comprises inserting a fastener 302 through a mounting hole 140A, 140B in the primary collar section 130 of the collar 112 and through a mounting hole 140A, 140B of the elongated beam 104, and attaching a pile connection 102 to the elongated beam 104 by inserting the elongated beam 104 through a gap 132 defined by a primary collar section 130 of a collar 112. The primary collar section 130 is configured to partially surround the elongated beam 104.

In certain embodiments, the method further includes inserting a second pile 108B into a second pile sleeve 110B of the pile connection 102 and driving the second pile 108B into the ground 106 to fix the elongated beam 104 to the ground 106. The second pile sleeve 110B is attached to the primary collar section 130.

In certain embodiments, the method further includes attaching a secondary collar section 300 to the primary collar section 130 such that the primary collar section 130 and the secondary collar section 300 fully surround the elongated beam 104.

It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the invention.

Many modifications and other embodiments of the embodiments set forth herein will come to mind to one skilled in the art to which the embodiments pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the description and claims are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. It is intended that the embodiments cover the modifications and variations of the embodiments, provided they come within the scope of the appended claims and their equivalents. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 

What is claimed is:
 1. A pile connection, comprising: a collar configured to attach to an elongated beam extending along a beam axis, the at least one collar comprising a primary collar section defining a gap, the primary collar section configured to partially surround the elongated beam; and a first pile sleeve comprising a first inlet, a first outlet, and a first outer surface extending therebetween, at least a portion of the first outer surface attached to the primary collar section, the first pile sleeve configured to receive a first pile.
 2. The pile connection of claim 1, wherein the collar comprises at least one of a circular cross-section, a rectangular cross-section, or a square cross-section.
 3. The pile connection of claim 1, wherein the primary collar section comprises a base wall, a first sidewall extending from the base wall, and a second sidewall extending from the base wall, the gap defined between a first front edge of the first sidewall and a second front edge of the second sidewall.
 4. The pile connection of claim 1, wherein the gap is larger than the elongated beam such that the primary collar section is configured to receive the elongated beam through the gap.
 5. The pile connection of claim 3, wherein the first sidewall comprises at least one first mounting hole proximate the first front edge, and the second sidewall comprises at least one second mounting hole proximate the second front edge.
 6. The pile connection of claim 1, further comprising a secondary collar section configured to attach to the primary collar section and partially surround the elongated beam; wherein the primary collar section and the secondary collar section fully surround the elongated beam.
 7. The pile connection of claim 1, further comprising a second pile sleeve comprising a second inlet, a second outlet, and a second outer surface extending therebetween, at least a portion of the second outer surface attached to the primary collar section, the second pile sleeve configured to receive a second pile; wherein the coupling is configured to attach the first pile sleeve to the elongated beam at a first side of the elongated beam, and attach the second pile sleeve to the elongated beam at a second side of the elongated beam.
 8. The pile connection of claim 7, wherein the pile connection comprises only two pile sleeves.
 9. The pile connection of claim 7, wherein the first pile sleeve and the second pile sleeve each comprise a rectangular cross-section.
 10. The pile connection of claim 7, wherein the first pile sleeve and the second pile sleeve are non-parallel to each other.
 11. The pile connection of claim 7, wherein the first pile sleeve and the second pile sleeve are aligned in a common plane.
 12. The pile connection of claim 7, wherein the primary collar section comprises a base wall, a first sidewall extending from the base wall, and a second sidewall extending from the base wall, the gap defined between a first front edge of the first sidewall and a second front edge of the second sidewall; wherein the first pile sleeve relative to the first sidewall is at a same angle as the second pile sleeve relative to the second sidewall; and wherein the first pile sleeve relative to the base wall is at a same angle as the second pile sleeve relative to the second sidewall.
 13. A support system, comprising: at least one elongated beam extending along a beam axis; at least one pile connection attached to the at least one elongated beam, the at least one pile connection comprising: a collar configured to attach to the elongated beam, the at least one collar comprising a primary collar section defining a gap, the primary collar section configured to partially surround the elongated beam; a first pile sleeve comprising a first inlet, a first outlet, and a first outer surface extending therebetween, at least a portion of the first outer surface attached to the primary collar section; and a first pile positioned within the first pile sleeve.
 14. The support system of claim 13, wherein the at least one pile connection further comprises a second pile sleeve comprising a second inlet, a second outlet, and a second outer surface extending therebetween, at least a portion of the second outer surface attached to the primary collar section; wherein the support system further comprises a second pile positioned within the second pile sleeve.
 15. The support system of claim 13, wherein the elongated beam comprises structural steel.
 16. The support system of claim 13, wherein the structural steel comprises circular tubing, rectangular tubing, square tubing, I-Beam, or W-Beam.
 17. A method for forming a support system, comprising: positioning an elongated beam relative to a ground, the elongated beam extending along a beam axis; attaching a pile connection to the elongated beam by inserting the elongated beam through a gap defined by a primary collar section of a collar, the primary collar section configured to partially surround the elongated beam; and inserting a first pile into a first pile sleeve of the pile connection and driving the first pile into the ground to fix the elongated beam to the ground, the first pile sleeve attached to the primary collar section.
 18. The method of claim 17, wherein attaching a pile connection to the elongated beam further comprises: inserting a fastener through a mounting hole in the primary collar section of the collar and through a mounting hole of the elongated beam.
 19. The method of claim 17, wherein the method further comprises inserting a second pile into a second pile sleeve of the pile connection and driving the second pile into the ground to fix the elongated beam to the ground, the second pile sleeve attached to the primary collar section.
 20. The method of claim 17, further comprising attaching a secondary collar section to the primary collar section such that the primary collar section and the secondary collar section fully surround the elongated beam. 